Apparatus for the manufacture of nonwoven webs and laminates

Abstract

Nonwoven laminates are made by a multi-station line comprising at least one spunbond die assembly and at least one meltblowing die assembly. Each station includes (a) a melt spinning die which can be selectively equipped with a spunbond die insert or a meltblowing die insert and (b) a moveable support structure for adjusting the proper die-to-collector distance, depending on the spunbond or meltblowing mode of operation. The multi-station line permits the selective manufacture of a variety of spunbond (S) and meltblown (M) laminates, including the S-M-S laminate.

What is claimed is:  
     
       1. An apparatus for the in-line manufacture of a laminate of thermoplastic layers comprising 
       (a) first and second side-by-side stations, each station having  
       (i) a vertically moveable support structure,  
       (ii) an extruder mounted on the moveable support structure,  
       (iii) a melt spinning die body mounted on the moveable support structure, said die body having a downwardly facing cavity formed therein, and  
       (iv) means for delivering a polymer melt from the extruder to the die body;  
       (b) a spunbond die insert mounted in the cavity of the die body of one of the stations and including means for receiving polymer melt from the die extruder and converting the melt into filaments;  
       (c) a meltblowing die insert mounted in the cavity of the die body of the other of the stations and including means for receiving polymer melt from the extruder and converting the melt into meltblown filaments, said spunbond die insert and said meltblowing die insert being interchangeable;  
       (d) a moveable filament collector positioned under the spunbond die insert and the meltblowing die insert for receiving filaments therefrom to form layers thereon; and  
       (e) means for selectively moving each support structure to adjust the distance of the die-to-collector for each station.  
     
     
       2. The apparatus of  claim 1 , wherein the spunbond die insert includes means for producing filaments having an average diameter of 12 to 50 microns, and the meltblowing die insert includes means for producing filaments having an average diameter of 1 to 10 microns. 
     
     
       3. The apparatus of  claim 1 , and further comprising means for bonding the two layers together. 
     
     
       4. The apparatus of  claim 1 , wherein the means for delivering polymer to the die body includes a positive displacement pump mounted on the moveable support structure.